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VIAIR 45040 450C Air Compressor Kit

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User Manual

This is the main product document for model 45040. Additionally, the document applies to other VIAIR models: 32530, 32533, 32534, 32538, 35030, 35033, 40040

The file format is pdf, 8 pages, you can download this manual here .

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IMPORTANT SAFETY INSTRUCTIONS
CAUTION - To reduce risk of electrical shock:
- Donotdisassemble.Donotattemptrepairsormodications.Refertoqualiedserviceagencies
forallserviceandrepairs.
- Donotusethisproductinanareawhereitcanfallorbepulledintowaterorotherliquids.
- Donotreachforthisproductifithasfallenintoliquid.
- Usethiscompressorwith12-voltor24-volt(P/N32538)DCsystemsonly.
- Thisproductshouldneverbeleftunattendedduringuse.
WARNING - To prevent injury:
- Neverallowchildrentooperatethiscompressor.Closesupervisionisnecessarywhenthiscompressor
isbeingusednearchildren.
- ThiscompressorwillbecomeveryHOTduringandimmediatelyafteruse.Donottouchanypartofthis
compressorwithbarehandsduringandimmediatelyafteruse.
- Donotusethisproductnearamesorexplosivematerialsorwhereaerosolproductsarebeingused.
- Donotoperatethisproductwhereoxygenisbeingadministered.
- Donotpumpanythingotherthanatmosphericair.
- Neverusethisproductwhilesleepyordrowsy.
- Donotuseanytoolsorattachmentswithoutrstdeterminingmaximumairpressureforthattool
or attachment.
- Neverpointanyairnozzleorairsprayertowardanotherpersonoranypartofthebody.
- ThisaircompressorisequippedwithanAutomaticResetThermalProtector,andcanautomatically
restartafterthethermalprotectorresets.Alwayscutoffpowersourcewhenthermalprotector
becomesactivated.
- Wearsafetyglassesorgoggleswhenoperatingthisproduct.
- Useonlyinwellventilatedareas.
INSTALLATION
Pleasereadandfollowtheinstallationinstructionscarefullytoavoidinjuryordamagetothe
compressorandyourvehicle.
Eachofouraircompressorsandpartshavebeencarefullyproducedandpackaged.Beforeyou
begininstallation,pleasefamiliarizeyourselfwithInstallationPartsList(Fig.1)ofthismanual.
Guidelines for Selecting Mounting Location:
Theselectionofpropermountinglocationforyouraircompressorwillhelpensurealongandtrouble
freecompressorservicelife.Pleasepaycloseattentiontothefollowingguidelines:
1. Select a FLAT,UPRIGHTANDSECURE location where the compressor can be mounted.
2.Tomaximizeaircompressorperformance,locatecompressorasCLOSETOTHEBATTERY as
possiblesothatlengthofpositiveleadwirerequiredisataminimum.
3.ChoosemountinglocationthatisascoolaspossibleandAWAYFROMHEATSOURCES.
Thecoolertheambienttemperature,thelesschancethecompressorwilloverheat.
4.Thiscompressorismoisture&dustresistant,butNOTDIRTORWATERPROOF. Do not mount
compressorinlocationswheretheunitislikelytocomeincontactwiththeelements.
5.Forcompressorwithremoteltermounting,selectcompressor’smountinglocationwhereairline
canberoutedfromcompressorairinlettoremoteinletairlter.Makesurethattheremoteinletair
lterislocatedinadrylocation,awayfromtheelements.
6.Youwillalsowanttoselectacompressormountinglocationwheretheleaderhosebracketcanbe
mounted to leader hose. (Not applicable to P/N 32534)
7.Ifitisnecessarytomounttheaircompressorfurtherawayfromthebattery,suchasinside
yourvehicleorinthebedofyourpickup,useapositiveleadwireforremoteinstallation.Referto
thewiregaugeguideonthebackofthismanual.
8.Donotmountcompressornearareaswhereammableliquidsarestored.
9.Usethreadsealantforproperttinginstallation.Threadtapeisnotrecommended.
Properlysealed,recommendedtorqueis12to15ft.lbs
USER MANUAL
325C - 350C - 400C - 450C COMPRESSOR KIT
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MOUNTING AND WIRING
1. Disconnectgroundcablefromvehicle’sbattery.
2. Temporarilypositiontheaircompressorinthelocationwhereitwillbemounted.
3. Routegroundwiretothenegativepostofthebatteryortoanappropriategroundingpointand
cutgroundwiretolengthasneeded.
4. Mountaircompressorwiththefoursetsofbolts,nuts,washers,andlockingwashersprovided.
(SeeFig.2forMountingInstructions)Useofthreadsealantrecommended.
5. NOTE:Forremoteinletairlterinstallation,refertoinstructionsincludedintheRemoteInletAir
FilterPack.
6. Thisaircompressormaybeequippedwithaheavydutyheatresistantleaderhose.Thisleader
hoseisdesignedtoprolongthelifeofyourairline.Donotremovethisleaderhosefromair
compressor. (Not applicable to P/N 32534)
7. IMPORTANT:Pleasenote,theleaderhosethatmaybeequippedwithyourcompressormay
alsohaveabuilt-ininlinecheckvalve.Donotremoveinlinecheckvalvefromleaderhoseif
soequipped.
8. Selectaproperlocationtomountleaderhosewithhosebracketprovided.Avoidlocations
whereleaderhosemaybecometangledwithwiresandotherhoses.
9. Tomounthosebracket,drillholewith3/16”drillbitandpushself–anchoringhosebracketpin
intohole.Routeleaderhosethroughhosebracketandsecurehosebypressingbracketclamp
into locked position.
10.Toremovehosefromthehosebracket,simplypressdownonthehoseclampreleasetabto
releasebracketclamp.(Fig.3)
11.Connectcompressor’spositiveleadwiretooneoftheleadsofyourpressureswitch.
12.Makesurethatyourcompressorsetupisproperlyfused.Forappropriatefusesize,refertoamp
drawofcompressorinthespecicationssectionofthismanual.
13.Alwayslocatefuseascloseaspossibletopowersource.
14.Beforeconnectingtopowersource,re-checktomakesurethatallconnectionsare
madeproperly.
15.Connectandtestcompressorsystembyrunningthecompressorforashorttimetobuildup
pressureinyourairtank.
16.Onceairpressurereachespresetcutoutpressureofyourpressureswitch,thecompressorwill
shutoff.Inspectallairlineconnectionsforleakswithsoapandwatersolution.Ifaleakis
detected,theairlinemaynotbecutsquarelyorpushedallthewayin.
(Fig. 1) 325C / 350C / 400C / 450C Compressor Installation Parts List:
A.HoseBracket(1pc) - N/A 32534
B.MountingBolts(4pcs)
C.FlatWashers(8pcs)
D.LockingWashers(4pcs)
E.Nuts(4pcs)
F.1/4”NPTFx3/8”BarbedFitting(1pc)
G.1/4”NPTMx3/8”BarbedFitting(1pc)
H.3/8”AirLine
I.AirLineClips(3pcs)
J.Screws(3pcs)
K.RemoteInletAirFilterwithFilterElement(1pc)
(Fig. 2) Compressor
Mounting Hardware
B.MountingBolt
C.FlatWasher
D.LockingWasher
E.Nut
K.VibrationIsolator
USER MANUAL
325C - 350C - 400C - 450C COMPRESSOR KIT
REDUCER
B
A
C D E
F
G
I
J
K
(Fig. 3) Leader Hose Bracket (N/A 32534)
L.HoseClamp
M.ClampReleaseTab
N.Self-AnchoringPin
B
C
C
D
E
K
REDUCER
L
M
N
H
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OPERATING INSTRUCTIONS
1. IMPORTANT:AlwaysoperatethecompressoratorbelowtheMAXIMUMPRESSURERATINGof
thecompressor.PleaserefertoApplication&SpecicationsSectionsofthismanualfordetails.
2.AlwaysobservetheMAXIMUMDUTYCYCLEoftheaircompressor.RefertoCompressor
ApplicationsandSpecicationsSectionsofthismanualfordetails.Operationexceeding
maximumpressureratingsand/ordutycyclewillresultindamagetotheaircompressor.
3.YouraircompressorisequippedwithanAUTOMATICTHERMALOVERLOADPROTECTOR.This
featureisdesignedtoprotecttheaircompressorfromoverheatingandcausingpermanent
damagetoyouraircompressor.Thethermaloverloadprotectorwillautomaticallycutpowerto
youraircompressorshouldtheinternaloperatingtemperatureoftheaircompressorriseabove
safelevelsduringexcessiveuse.
4.Shouldatanytimeduringuse,youraircompressorautomaticallyshutsoff;donotattemptto
restartit.Turnoffpowerandallowunittocoolforabout30minutes.ThiswillallowtheThermal
OverloadProtectortoresetsoyoucansafelyresumeuseoftheaircompressor.
5.Topreventdischargeofyourvehicle’sbattery,andenhanceperformance,keepthevehicle’s
enginerunningwhileusingthecompressor.
6.Onlyoperatecompressorinwellventilatedareas.
7.Theuseofarelayisstronglyrecommendedforinstallationofthiscompressor,butnotincluded.
(40-amprelayvalueorhigherpercompressorrecommended).
MAINTENANCE & REPAIRS
1.Periodicallycheckallelectricalandttingsconnections.Cleanandtightenasneeded.
2.Periodicallycheckallmountingscrews.Tightenasneeded.
3.ReplaceAirFilterElementperiodically.Replacementfrequencydependsonoperatingfrequencyand
operatingenvironment.Forfrequentuseindustyenvironment,werecommendthatyoureplaceair
lterelementatleastonceamonth.
4.Regularlycleandustanddirtfromcompressorcoolingnsandmotorhousing.
5.Youraircompressorisequippedwithapermanentlylubricated,maintenance-freemotor.Nevertryto
lubricate the compressor.
6.AllrepairsshouldbeperformedbyManufacturerorManufacturer’sAuthorizedServiceAgenciesonly.
CAUTION:
Nevertouchtheaircompressororttingsconnectedtotheaircompressor,withbarehandsduring
orimmediatelyafteruse.Theleaderhoseandttingsconnectedtoleaderhosewillbecomevery
HOTduringandafteruse.Ifnecessary,wearheatresistantglovestohandlettings,airline,and
leader hose.
USER MANUAL
325C - 350C - 400C - 450C COMPRESSOR KIT
RELAY WIRING SCHEMATIC
Pressure Switch
86
Fused
12-Volt
30
To Ground
85
87
Compressor
(+) Lead
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SPECIFICATIONS
•PartNo.32530/32533/32534/32538/325CAirCompressorKit/Silver&Chrome(CESpec.)
MotorVoltage: 12volts
24volts(32538)
Max.CurrentConsumption: 21amps-12v
13amps-24v
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72ºF&100PSI): 33%
MinutesOn/Off(@72ºF&100PSI): 20On/40Off
Max.RestartPressure:  200PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Auto.ResetThermalProtection: Yes
Dimensions: 8”Lx4”Wx6.75H”
NetWeight: 7.50Lbs.
•PartNo.35030&35033/350CAirCompressorKit/Silver&Chrome(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 20Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72°F&100PSI): 100%
MinutesOn/Off(@72°F&100PSI): 1HourRunTime
Max.RestartPressure: 200PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Auto.ResetThermalProtection: Yes
Dimensions: 9”Lx4”Wx6.75H”
NetWeight: 8.55Lbs.
•PartNo.40040/400CAirCompressorKit/Silver(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 28Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72°F&100PSI): 33%
MinutesOn/Off(@72°F&100PSI): 20On/40Off
Max.RestartPressure: 200PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Auto.ResetThermalProtection: Yes
Dimensions: 9”Lx4”Wx6.75H”
NetWeight: 8.65Lbs.
•PartNo.45040/450CAirCompressorKit/Silver(CESpec.)
MotorVoltage: 12Volts
Max.CurrentConsumption: 23Amps
MotorType: PermanentMagnetic
Horsepower: 1/4
Max.WorkingPressure: 150PSI
Max.DutyCycle(@72°F&100PSI): 100%
MinutesOn/Off(@72°F&100PSI): 1HourRunTime
Max.RestartPressure: 200PSI
Max.AmbientTemperature: 158°F
Min.AmbientTemperature: -40°F
Auto.ResetThermalProtection: Yes
Dimensions: 10.6”Lx4”Wx6.87H”
NetWeight: 10.80Lbs.
USER MANUAL
325C - 350C - 400C - 450C COMPRESSOR KIT
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COMPRESSOR APPLICATION GUIDE
Toensurethatyougetthehighestlevelofsatisfactionfromyourcompressor’sperformance,referto
information below:
VIAIR COMPRESSOR REFERENCE CHART
COMPRESSORSERIES DUTYCYCLE MAX.WORKINGPRESSURE
(100PSI@72°F)
090SERIES 9% 120PSI
092SERIES 9% 120PSI
095SERIES 9% 120PSI
097SERIES 10% 130PSI
098SERIES 10% 130PSI
100SERIES 15% 130PSI
250IGSERIES 100% 150PSI
275SERIES 25% 150PSI
280SERIES 30% 150PSI
325SERIES 33% 150PSI
330IGSERIES 100% 150PSI
350SERIES 100% 150PSI
380SERIES 100% 200PSI
*55%
400SERIES 33% 150PSI
420SERIES 33% 150PSI
444SERIES 100% 200PSI
*50%
450SERIES 100% 150PSI
450IGSERIES 100% 150PSI
460SERIES 100% 150PSI
480SERIES 100% 200PSI
*50%
*Duty Cycle at 200 PSI and 72°F.
ABOUT COMPRESSOR DUTY CYCLE:
Dutycyclereferstotheamountoftimeacompressorcanbe
operatedinagiventimeperiodat100PSI,andastandardambienttemperatureof72°F.Itis
commonlyexpressedinpercentageformat:Compressorontime÷(ontime+offtime)=DutyCycle
%.
ONE-HOUR DUTY CYCLE MINUTES ON /
(100PSI@72°F) MINUTES OFF
9% 5Min.On/55Min.Off
10% 6Min.On/54Min.Off
15% 9Min.On/51Min.Off
20% 12Min.On/48Min.Off
25% 15Min.On/45Min.Off
30% 18Min.On/42Min.Off
33% 20Min.On/40Min.Off
50% 30Min.On/30Min.Off
100% 1HourRunTime
NOTE:Allcompressors,regardlessofrateddutycycle,requiresufcientresttimeinbetweencycles
toallowforpartialorcompleteheatdissipation.Heatdissipationratesmayvarydependingon
ambienttemperaturesandoperatingconditions.
ABOUT RATED WORKING PRESSURE:
Toensuretroublefreeservicelifeofyourcompressor,alwaysoperatecompressorwithinrated
workingpressureofthecompressor.Neveruseapressureswitchwithahighercut-offpressure
thancompressor’sratedworkingpressure.
USER MANUAL
325C - 350C - 400C - 450C COMPRESSOR KIT
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325C - 350C - 400C - 450C COMPRESSOR KIT
TROUBLESHOOTING GUIDE:
Tank pressure drops when
compressor(s)shutoff
1.Loosedraincock
2.Checkvalveleaking
3.Looseconnections
1.Tightendraincock
2.Replacecheckvalveor
compressor
3.Checkallconnectionswith
soap and water solution
andtighten
Compressorruns
continuouslyandairow
lower than normal
1.Excessiveairusage
2.Looseconnections
3.Wornpistonringorinlet
valve.
4.Cloggedairlterelement
1.Decreaseairusage
2.Checkallconnectionswith
soap and water solution
andtighten.
3.Replacecompressor
4.Replaceairlterelement
Compressorruns
continuouslycausing
safetyvalve(ifequipped)
to open
1.Faultypressureswitch
2.Defectivesafetyvalve
1.Replacepressureswitch
2.Replacesafetyvalve
Excessivemoisturein
discharge
1.Excessivewaterinairtank
2.Highhumidity
1.Draintank,tilttanktodrain.
Draintankmorefrequently
2.Movecompressortoarea
withlesshumidity,oruse
airlinelter
Compressorwillnotrun 1.Nopower,orpowerswitch
inOFFposition
2.Blownfuse
3.Motoroverheats
4.Faultypressureswitch
(ifhookeduptoa
pressureswitch).
1.Makesurecompressor
switchisON
2. Disconnect compressor
frompowersource,replace
fuse.(RefertoSpecications
section for correct
fuseamperage)
3.Letcompressorcoolofffor
about30minutestoallow
thermaloverloadswitchtoreset.
4.Replacepressureswitch
Thermaloverload
protector cuts out
repeatedly
1.Lackofproperventilationor
ambienttemperatureistoohigh
2.Compressorvalvesfailed
1.Movecompressortowell
ventilatedarea,orareawith
lower ambient temperature
2.Replacecompressor
Excessiveknocking
orrattling
1.Loosemountingbolts
2.Wornbearingoneccentricor
motor shaft
3.Cylinderorpistonringisworn
1.Tightenbolts
2.Replacebearingor
pistonassembly
3.Replacepistonorcompressor
CAUTION: NEVER DISASSEMBLE COMPRESSOR WHILE
COMPRESSOR IS PRESSURIZED.
USER MANUAL
PROBLEM:
POSSIBLECAUSE(S) CORRECTIVEACTION
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USER MANUAL
325C - 350C - 400C - 450C COMPRESSOR KIT
Wiring Diagram:
(Fuse Not Included)
SINGLE “C” MODEL
COMPRESSOR WIRING DIAGRAM
15 Edelman
Irvine, CA 92618
949-585-0011
www.viaircorp.com
87
86
30
85
+
-
Battery
To Keyed
Power Source
40A Relay
Fuse
Pressure
Switch
Rev.1
325C, 350C @ 30A
400C, 450C @ 40A
AMERICAN WIRE GAUGE GUIDE 12-VOLT: AMERICAN WIRE GAUGE GUIDE 24-VOLT:
AmpDraw
Lengthofwirefrombatteryto
compressor(infeet)
5 10 15 20
5 16 16 16 14
10 16
14 12 10
15 16 12 10 10
20 14 10 10 8
25 14 10 8 6
30 12 10 8 6
40 12
8 6 6
50 10 6 6 4
60 10 6 4 4
AmpDraw
Lengthofwirefrombatteryto
compressor(infeet)
5 10 15 20
5 16 16 16 16
10 16 16 16 14
15 16 16 14 12
20 16
14 12 10
25 16 12 12 10
30 16 12 10 10
40 14 10 10 8
50
14 10 8 6
60 12 10 8 6
LIMITED WARRANTY:
VIAIRCorporationwarrantsthisproduct,whenproperlyinstalledandundernormalconditionsof
use,tobefreefromdefectsinworkmanshipandmaterialsforaperiodofoneyearfromitsoriginal
dateofpurchase.Toreceivewarrantyserviceorrepair,pleasecontactVIAIRCorporation.
Returnsshouldbemadewithinoneyearofthedateofpurchase,afteraReturnGoodsAuthorization
(RGA)numberhasbeenassignedbyVIAIRCorporation.ToobtainRGA,faxacopyofyourreceipt
to(949)585-0188.Forcompletewarrantydetails,pleasevisit:www.viaircorp.com/warranty
PLEASE NOTE:
THISWARRANTYCOVERSPRODUCTDEFECTSONLY;ITDOESNOTCOVERINCIDENTAL
ORCONSEQUENTIALDAMAGESASRESULTOFMISUSEORABUSE.
15EDELMAN•IRVINE,CA92618
TEL:(949)585-0011•FAX:(949)585-0188
www.viaircorp.com

Specifications

Indexed Terms: Air Compressor

VIAIR 45040 Questions and Answers

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Questions and Answers